SOP # FCX-23

FCX Department of Occupational Health and Safety Revision # Rev. 1

Supersedes 0: New
X High
Interaction with Heavy Mobile Equipment - Surface Task Risk
Medium
Road Design, Light Vehicles & Ground Personnel Low
NA
Approval Date: February 3, 2017 Original Date: August 2015

Contents
1.0 Policy......................................................................................................................................2
2.0 Responsibilities and Duties......................................................................................................3
2.1 Management ............................................................................................................................... 3
2.2 Health and Safety ...................................................................................................................... 4
2.3 Supervisors .......................................................................................................................................... 4
2.4 Contractors ......................................................................................................................................... 5
2.5 Contractor Management .................................................................................................................... 6
2.6 Employees .......................................................................................................................................... 6
3.0 Program Elements & Requirements .........................................................................................6
3.1 Separation of Heavy Equipment and Light Vehicles ..................................................................... 7
3.2 Separation of Heavy Equipment and Pedestrians ........................................................................ 8
3.4 Roads and Intersections .............................................................................................................. 10
3.5 Passing Procedures ..................................................................................................................... 12
3.6 Light Vehicle Requirements ........................................................................................................ 13
3.7 Perimeter Security and Lockout Tagout Tryout of Equipment ................................................... 14
4.0 Equipment – Technology ....................................................................................................... 15
5.0 Training ................................................................................................................................ 15
6.0 Audits ................................................................................................................................... 16
7.0 Variance ............................................................................................................................... 16
8.0 Definitions ............................................................................................................................ 17
9.0 References............................................................................................................................ 18
10.0 Records ................................................................................................................................ 18
11.0 Revision History .................................................................................................................... 18
Appendix A Examples and Forms ...................................................................................................... 25
1.0 Policy

This document establishes the minimum requirements and procedures for the health and safety of
Freeport-McMoRan employees and contract personnel where there could be interaction between
heavy equipment and light vehicles or people.

Policy All Freeport-McMoRan (FCX) locations where heavy equipment is utilized will
at a minimum adopt this policy and ensure that all site standard operating
procedures are aligned with it.

Scope This policy covers all FCX employees and contractors that may interact with
heavy mobile equipment.

Heavy mobile equipment shall include:

 Haul trucks
 Articulating trucks
 Loaders
 Track dozers/bulldozers
 Rubber tire dozer
 Motor grader/blades
 Trackhoes/backhoes
 Mobile cranes
 Shovels
 Water trucks
 Scrapers
 Drills
 Compactors
 Slag haulers
 Forklifts (20k lbs or greater)
 Other heavy mobile equipment that interact with smaller equipment
and pedestrians
2.0 Responsibilities and Duties

2.1 Management

It is management’s responsibility to ensure compliance with this policy, procedure and the
expectations outlined below.

Maintain Equipment
Ensure all equipment is in good working order and that regular preventative
in Good Working
maintenance procedures are in place. Where a defect or equipment issue will
Order
not allow safe operation, ensure equipment is not operated until such repairs
can be completed.

Ensure Proper
Ensure that all personnel that may interact with heavy mobile equipment are
Employee Training
properly trained per the requirements outlined within this document and with
pertinent other regional, federal and state regulations. Ensure employees are
competent and qualified to operate equipment.

Ensure Periodic
Ensure periodic engineering reviews of mine roads, intersections, light vehicle
Engineering
access, tie-down areas (haul truck staging areas), and heavy traffic areas such
Reviews are
as shops are conducted.
Conducted

Review Contractor Ensure that contractors working on FCX property are aware of these
Requirements requirements and have been trained.

Provide Equipment
Provide all necessary equipment and resources needed to safely operate
and Resources
equipment.

Maintain Documents
Maintain all completed inspections, documentation and training records
Control
according to the FCX -Records Retention Policy.

Identify Critical Risks

Ensure that critical risks associated with interaction between heavy equipment,
and Critical Controls
light vehicles, and people are identified and critical controls to reduce or
mitigate those risks are in place. Ensure that leadership conducts periodic
audits of these controls to verify use and effectiveness.

Perform Periodic
In conjunction with the Health and Safety department, conduct periodic audits
Audits of Process
of the overall interaction with heavy mobile equipment to ensure compliance.

Contractor Bidding
Ensure that contractor management is aware of this Policy and the appropriate
and Selection
language is included in contracts.
2.2 Health and Safety

It is the H&S Department’s responsibility to support compliance with this policy, procedure and the
expectations outlined below.

Perform Periodic The H&S Department will periodically audit for compliance and risk of the
Audits interactions between mobile equipment, light vehicles and people to identify
issues and work with management to develop solutions.

Inspection of contractor mobile equipment brought on site to ensure it meets

minimum standards.

Maintain Rescue The H&S Department in conjunction with site management will maintain
Team Capabilities adequate rescue capabilities (on-site team or 3rd party team), and ensure
these teams are trained in accordance with the requirements outlined within
this document. Significant incidents involving heavy equipment interactions
with light vehicles and people risks should be evaluated for rescue capabilities.
These drills shall consider all safety, environmental and business continuity
aspects.

Note: If a site must rely on third-party rescue, H&S and/or environmental

personnel must audit training and rescue capability of the third party.

Contracts Selection Work with contracts management to review the requirements of this Policy
and Bidding with contractors during the bidding process.

Review contractor safety plans to ensure elements of this Policy are included
where applicable.

2.3 Supervisors

It is the supervisor’s responsibility to verify compliance with this policy, procedure and the
expectations outlined below.

Maintain Equipment Verify all equipment is in good working order and that regular preventative
in Good Working maintenance procedures are in place. Where a defect or equipment issue will
Order not allow safe operation, ensure equipment is not operated until such repairs
can be completed.

Verify Proper Verify that all personnel that may interact with heavy mobile equipment are
Employee Training properly trained per the requirements outlined within this document and with
pertinent regional, federal and state regulations. Ensure employees are
competent and qualified to operate equipment.
Provide Equipment Provide all necessary equipment and resources needed to safely operate
and Resources equipment.

Maintain Documents Maintain all completed inspections, documentation and training records
Control according to the FCX -Records Retention Policy.

Identify Critical Risks Verify that critical risks associated with interaction between heavy equipment,
and Critical Controls light vehicles, and people are identified and critical controls to reduce or
mitigate those risks are in place. Verify that employees are conducting a pre-
task risk review.

Evaluate area of responsibility for new risks or changes that could pose risk and
ensure critical controls are in place to mitigate risk. Ensure that a risk review is
completed for any new roads, changes in traffic patterns, or other changes
which could impact safe interaction of heavy equipment with light vehicles or
pedestrians to ensure that adequate controls are in place.

Ensure that any new risks identified are passed on to incoming crews.

Enlist help from engineering, health and safety or other resources as necessary
to improve critical controls.

Perform Periodic In conjunction with the Health and Safety department, conduct periodic audits
Audits of Process of the overall Interaction with Heavy Mobile Equipment to ensure compliance.

Contractor Ensure contractors working in area of responsibility have received appropriate

Compliance information and training on the area-specific hazards. Monitor contractors for
compliance.

2.4 Contractors

It is a Contractor’s responsibility to provide properly trained employees and to comply with

this policy.

Meet FCX Policy Any contractors working for FCX will meet or exceed the requirements of this
Requirements policy and shall comply with the FCX Contractor Safety Manual while on FCX
property and within company-owned facilities.

Identify Critical Risks Ensure that critical risks associated with interaction between heavy equipment,
and Critical Controls light vehicles, and people are identified and critical controls to reduce or
mitigate those risks are in place. Ensure that contract leadership conducts
periodic audits of these controls to verify use and effectiveness.

Perform Periodic Conduct periodic audits of the overall Interaction with heavy mobile
Process Audits equipment, light vehicles and people to ensure compliance.
2.5 Contractor Management
It is the responsibility of Contractor Management to ensure elements of this Policy are included in
the contract language for contractor qualification, bidding and selection for work on FCX property.

Contractor Selection Ensure that contractors understand the requirements of this Policy and the
and Bidding training necessary to operate and interact with heavy mobile equipment.

Contractor Ensure contractors receive minimum equipment requirements as well as

Equipment requirements for inspections and maintenance for mobile equipment.
Requirements
Perform periodic audits of contractor maintenance records and procedures
for mobile equipment inspection and maintenance.

2.6 Employees
It is the responsibility of FCX employees to complete proper training and comply with this Policy.

Communicate Employees are expected to correct or report to Supervisors and/or Health &
Hazardous Safety Representatives if hazardous conditions or actions arise which may
Conditions cause injury to any employee before proceeding with further workplace
activities.

Maintain Training Training must be completed according to the training section and maintained
through refreshers as specified in site training plan. Employees must not
utilize a piece of mobile equipment or interact with heavy mobile equipment
without the proper documented training.

Employees will abide by all training and instruction given in In-pit Driver
Training and other safety training received.

Perform Pre-task Each individual is responsible to ensure that the critical controls are in place
Risk Assessments for the task they will perform prior to starting work. Critical controls should
be identified using the appropriate tools (ex: pre-shift equipment inspection,
work area inspection, job hazard analysis, job safety analysis.)

Situational risks must also be evaluated to determine if something in the area

creates any additional risks (ex., weather, other work in the area that poses
new risk).

3.0 Program Elements & Requirements

Each site will ensure that site-specific procedures comply with this Policy. All employees will comply
with site-specific procedures.
Use of Cell Phones No one shall use cell phones or other personal electronic devices while operating
and Other Electronic equipment or vehicles. All sites shall comply with the FCX – Communication
Devices Policy.

3.1 Separation of Heavy Equipment and Light Vehicles

Evaluation of areas where heavy equipment and light vehicles interact shall be conducted to look for
opportunities to eliminate the interactions utilizing the checklist in the Appendix.

Light Vehicle Access Sites will provide light vehicle access (LVA) to main shop and office areas that
Roads are physically separated from haul truck and heavy equipment traffic.
Additional LVA roads will be established whenever possible in other areas
where heavy equipment is operating.

Where LVA roads are required to cross haul roads, the use of tunnels shall be
evaluated.

Haul trucks shall sound their horn when approaching vendor routes or
designated LVA intersections on main haulage roads.

Turnouts at Evaluate opportunities for installation of LVA turnouts (orejas) at intersections

Intersections to separate light vehicles from haul trucks and provide better visibility.

Heavy Equipment Evaluate re-routing or using other methods where feasible.

Crossings on
Highways or other Where significant interaction or anytime haul traffic crosses public roads:
Non-mine Roads  Evaluate the use of a tunnel for these crossings. Or a minimum, signal
lights and/or signs and crossing gates shall be used to control
interaction between light vehicles and heavy equipment.

 A flagger or crossing guard shall be present to manage the intersection

for all public roadways.

Ensure that Department of Transportation or other regulatory agencies are

involved in the evaluation and planning and proper permits are acquired.

Parking Small equipment shall not park in the blind spot of a haul truck or other large
equipment without additional controls being in place. If light vehicles, such as
mechanical trucks, need to park closer to the equipment, then proper lockout
procedures must be followed prior to light vehicle parking within blind area.

Heavy equipment shall utilize windrows, wheel ditches, chocks or other means
to prevent equipment from movement based on the grade.

Approaching Heavy Approach shall never be made from the blind area of the equipment. Positive
Equipment radio contact shall be made before approaching heavy mobile equipment.
 When radio contact cannot be established, visual contact with the operator
must be made prior to approaching. Visual contact must be maintained as
approaching.

Operators of haul truck, loading units, water trucks (and other equipment as
determined by site) are required to secure vehicle and be out of the operator’s
cab before others approach the equipment. Visual contact is to be maintained
with those approaching.

Sites will establish procedures for non-routine situations (i.e., emergency or

non-responsive operator).

3.2 Separation of Heavy Equipment and Pedestrians

Evaluation of areas where heavy equipment and pedestrians (people) interact shall be conducted to look for
opportunities to eliminate the interactions.

Pedestrian Sites will provide designated pedestrian walkways or paths wherever there is
Walkways or Paths regular interaction with heavy equipment and pedestrians.

Pedestrian crossings will be provided where pedestrians need to regularly cross

roads. Crossings must be well signed for both pedestrians and equipment.
Adequate lighting will be provided where pedestrian walkways or paths exist.

Where possible a pedestrian crossing light (traffic signal) shall be provided.

Ground Crews All ground personnel shall wear PPE required for the area as well as a high
(leaching, surveyors, visibility and reflective vest or reflective clothing. This clothing needs to be highly
cable crew) visible both day and night.

When there are ground personnel that will be working on or near mine roads, a
pre-task risk evaluation must be conducted to identify critical controls that will be
implemented to separate these individuals from interaction with heavy mobile
equipment. Berms and safe distance requirements are potential controls.

Warning devices shall be utilized to communicate the presence of ground crews

such as: signs, lights, radio announcement by Dispatch or Control Room.

Flaggers or Spotters Flaggers or spotters shall be provided with a vehicle or shack. A radio must be
provided for communications. A high visibility and reflective vest or reflective
clothing will also be required.

Shops When moving large equipment in and out of the shop, spotters will be utilized.
 Emergency Protocol Each site shall evaluate and establish emergency procedures for heavy equipment
incidents. These procedures shall include safe retrieval of personnel and traffic
management protocol.

Personal Protective Employees and contractors on the ground around heavy equipment or light
Equipment vehicles shall wear a reflective safety vest or reflective clothing except in
designated areas such as shops, parking lots for personal vehicles, secured
perimeters and other designated areas.
3.3 Tie-down (Q-points)

Each tie-down area will be evaluated to ensure proper controls are in place, with a focus on eliminating
interactions between heavy equipment, light vehicles and pedestrians.

Separation between Tie-down areas shall be designed to provide a physical barrier (such as a berm)
Haul Trucks and between haul trucks and light vehicles. Example photo provided in Appendix.
Light Vehicles

Minimum These minimum requirements will be applied to all tie down areas.
Requirements  Support equipment shall be separated from haul trucks in designated
areas (Note: loading equipment may be parked with matched haul
trucks)
 Wheel ditch for equipment
 Forward travel only for exiting equipment (note: ok to back into the
parking ditch)
 Restricted from small equipment not involved in shift change
Supervisor vehicles are allowed in this area during shift change when
necessary.
 There shall be a minimum of 15 feet between haul trucks when parked
side-by-side; additional clearance will be needed for “in-line” parking
based on size of equipment
 Slots shall be provided in berms for personnel to enter and exit
 Equipment shall go to the forward most parking position or from right
to left as facing the equipment whichever applies
 Spare trucks left on the tie-down will be moved to the right (as facing
the equipment) after shift change is over, properly secured and
shutdown.
 Risk assessments shall be completed by all sites to determine the need
for additional requirements.

Shift Change Employee transport vehicles shall contact mine dispatch on the radio prior to
Procedures entering the pit and after exiting the tie-down area.

Haul trucks will not enter or leave the tie-down area until the employee
transport vehicle leaves the tie-down area. Other activities away from Tie-
down area may proceed as normal.
 Each site will develop procedures for non-routine situations where there is a
stray driver or heavy equipment that was not at the tie-down area at the
appropriate time.
3.4 Roads and Intersections

All roads and intersections will be evaluated for proper controls to ensure that all authorized
equipment can travel safely.

Haul Road Haul roads shall be constructed and maintained to ensure safe operation.
Construction Where conditions do not allow safe passage, additional controls shall be
applied or roads shall be closed until maintenance occurs.

Surface haul roads should be 3.5 times as wide as the largest vehicle on the
road. For a 793 this is 85 feet between the berms (96 feet for 930Es).

Haul roads should be constructed at 10% grades or lower where specific safety
considerations determine lower grade design requirements. Grades steeper
than 10% should be minimized and shall not exceed 15%. Utilize the
equipment manufacturer’s recommendations for the maximum grades of
articulating trucks used on site.

Haul roads should be designed to minimize the use of sharp turns. If sharp
turns are required, the road shall be widened to more than 4-4.5 truck widths
and employ super elevations to help the trucks turn. Sharp turns at
intersections will not be allowed.

Berms shall be constructed to a minimum mid-axle height of the largest vehicle

to travel on that road. At the base of steep ramps or where significant drop-
offs exist, a review will be conducted to determine if larger berms shall be
constructed to prevent equipment from going through the berm. Wider,
rather than taller, berms are preferred in order to maximize visibility.
Consideration for visibility for light vehicles shall be included in the evaluation.

Where road requirements above cannot be met, other controls must be put in
place to address the risk.

Intersections An intersection refers to anywhere multiple heavy equipment roads intersect

or where light vehicle roads meet a road used by heavy equipment. Light
vehicle support equipment access to haulage roads, and other heavy
equipment roads, must have consideration for adequate line of sight to heavy
equipment.

Intersections shall be clearly signed for heavy and light vehicles.

Intersections need to be carefully located and constructed to ensure adequate

visibility.
  For intersections on grades, 300 feet of sight distance is needed to
allow a fully loaded haul truck to come to a stop.
 For intersections on flat ground, 175 feet of sight distance is needed to
allow a fully loaded haul truck to come to a stop.
 Intersections should be avoided on the inside of curves and on the
crests of hills due to the limited visibility in those areas.
 All intersections should be constructed as right angle intersections. “T”
intersections should be encouraged while “Y” intersections should be
avoided.

If adequate sight distance is not available, then additional controls must be

applied.

Intersections shall be regularly audited to ensure there are no objects that

restrict visibility. These objects include but are not limited to; vegetation,
signs, utilities, power poles, buildings, berms.

Center berms or other separating traffic control devices should be utilized at

intersections and on sharp curves to separate two-way traffic and prevent
traffic from taking a shortcut through an intersection.

Light vehicles should be physically separated from haul trucks at intersections

whenever possible to minimize haul truck / light vehicle interaction. Light
vehicle entry points onto haul roads should be minimized and separated from
major intersections.

If possible, intersections should be illuminated at night and the lights should be

directed so they do not obscure the vision of either light vehicle or haul truck
operators.

The right-of-ways should be adequately signed and included in training. The

following vehicles have right-of-way over light vehicles:
 Larger equipment
 Loaded haul trucks
 Trucks to the blind side of larger equipment
 Emergency vehicles
 Vehicles carrying explosives

When in doubt, stop and communicate.

Speed Limits Speed limits shall be based on equipment manufacturer recommendations but
with haul road speed limits being no more than 35 mph and shop area speed
limits at 5-15 mph depending on pedestrian and light vehicle traffic in the area.

Speeds should be reduced based on the physical conditions of the road such as
width, surface conditions, intersections, visibility, and presence of ground
crews as well as for weather conditions.
Haul Road Left hand traffic for surface mines shall be utilized within the mine areas or
Operations wherever there may be interaction with haul trucks and large water trucks.
Adequate signage and crossovers also need to be provided.

Roads should be adequately watered to control dust and ensure visibility for
haul truck operators and light vehicle operators. Water truck operators need
to spot-water and not over-water to ensure adequate traction for all vehicles.

Permanently closed roadways shall be bermed off. Haul truck tires may be
used to temporarily restrict access to haul trucks and large water trucks.

Where haul trucks are hauling loaded downhill additional controls shall be
implemented to minimize the risk (Ex., straddle berms, run-away ramp, signage
for lower gear/speeds, RAMP Tech monitoring.)

Signs should be utilized on all roads to indicate speed limits. Use of signage
shall be evaluated on all roadways to warn for hazardous conditions and placed
at appropriate locations. Examples of signs that may be needed: intersection,
narrow roadway, obstructed view, road damage, indication of right-of-way,
personnel working, etc. Signs shall be regularly maintained and readable.

During adverse weather conditions, speed limits will be reduced and traffic
should be limited to only necessary travel. If weather conditions prevent safe
operation, traffic shall be stopped until weather clears. In areas where fog or
snow are frequent, guideposts shall be used to delineate edge of road.

One-way traffic signs will be utilized to define direction of traffic flow.

In left hand traffic areas, haul trucks and large water trucks will not make U-
turns without confirmation that the right side of the vehicle is clear of other
equipment or pedestrians.

3.5 Passing Procedures

All sites will establish safe passing procedures for equipment and light vehicles.

Haul trucks Prior to passing haul trucks, radio contact must be made with the operators.
The light vehicle operator must tell the haul truck operator his equipment call
number. Once direct contact is made, the haul truck operator must respond
with the same equipment call number and acknowledge it is clear to pass.
Note that the light vehicle operator is responsible for making sure the road is
clear of oncoming traffic. If contact cannot be made, passing will not occur.

Passing haul trucks on the left side in left-hand traffic areas shall not be
permitted.
 Only one vehicle at a time may pass a haul truck or other piece of large
equipment. While passing, the light vehicle should remain far enough to the
right to avoid hazards associated with spillage and tire blowouts.

Where radio communication is not available, passing shall be prohibited

without an approved variance (see FCX – Global Significant Risk Variance
Process).

Other large When passing other large equipment, radio contact shall be made. If radio
equipment contact cannot be made, passing will be prohibited.

When radio contact cannot be made with a stopped or downed piece of

equipment, then visual contact with the operator in conjunction with hand
signals may be used.
3.6 Light Vehicle Requirements

Light vehicles traveling into the mine shall meet minimum requirements and be kept in good working
order.

Periodic All light vehicles used to transport personnel shall be inspected before being
maintenance and operated. Light vehicles shall be regularly maintained at intervals not to
inspection exceed every 3 months or 3000 miles. (Time and duration should be based on
requirements conditions.) Inspections shall consist of:
 Steering Components
 Brake Components
 Drive Lines and U Joints
 Lights
 Gauges
 Equipment Numbers
 Tires/Rims/Lugs
 Suspensions
 Frame for Cracks
 Seatbelts
 Glass/Wipers
 Fluid Levels
 Buggy whip/light

Worn components will be replaced before the vehicle is released for operation.
Any safety items (*) marked on pre-use inspections checklists as “bad order” or
not functional will be repaired before the equipment is released.

Minimum All vehicles entering the mine must have a two-way radio and buggy whip with
requirements for pit some form of working light at all times. Areas where buggy whips are required
entry will be identified with signage. Buggy whips must be a minimum of 12 feet;
measured from ground level to the top of the light.
 Lights shall be used to indicate types of equipment and to make them more
visible:
 Blue is reserved for support equipment as needed to restrict passing
 Amber for visibility as needed
 Red for emergency and blasting
 Flashing strobe lights on transport vehicles (buses and man vans) in a
color that can be seen in various weather conditions

Haul trucks shall have numbering with LED lights or a minimum reflective tape
and be large enough to be seen by other vehicles.

Light vehicles will have numbering a minimum size of 4 inch lettering on each
side with one on the rear when possible. Lettering color will be distinguishable
compared to the vehicle color. Number series/sequence should be simplistic
and well organized for easy identification.

All-terrain Vehicles (ATVs), Utility Terrain Vehicles (UTVs) and slow-moving

small equipment must be escorted or have working amber strobe light when
operating on mine haul roads.

3.7 Perimeter Security and Lockout Tagout Tryout of Equipment

Lockout, tagout, tryout of equipment will be in accordance with the FCX – lockout Tagout Tryout
Policy. Perimeter security shall be utilized when LOTOTO is not required but there is a need to
communicate the equipment is in control of an operator.

Pre-use inspections When an employee leaves the cab of the truck and it must remain running
and Ground Breaks (during pre-shift inspections and ground breaks for example) the operator
must signify that the equipment is in use and ensure that control of the energy
source is maintained. Perimeter security must be utilized to communicate to
others that the truck is under control of an operator that is currently on the
ground. Examples include but are not limited to: locks and tags on ladder
gates, cable with a clamp with a lock and tag, signs and flags, etc. Use of park
brake light indication for haul trucks should be evaluated for additional
communication that the truck park brake is set.

Large loading equipment, water trucks, drills also shall have a perimeter
security procedure established.

Maintenance and When maintenance is being performed lockout tagout tryout procedures
Fueling according to the FCX – Lockout Tagout Tryout Policy must be followed for
(Lockout Tagout anyone that will get on, under, or work on the heavy mobile equipment.
Tryout)
The following minimum standards must be in place when fueling:
 Equipment secured
 Pedestrian walkways defined
  LOTOTO and/or perimeter procedures must be followed by all in the
area

4.0 Equipment – Technology

As various forms of technology become available that introduce improved controls to reduce risk,
each site will install these technologies as feasible or as required. Sites should work with the FCX
Technology Center - Mining to evaluate new and existing equipment technologies.

In-cab Fatigue All sites will install and maintain the in-cab fatigue monitoring systems for
Monitoring System surface haul trucks and other equipment where feasible. Maintenance
(Drivers State programs will be established to keep units operational.
Sensing – DSS)
Each site is required to maintain a fatigue management program that
includes: communication, training, fit-for-duty and supervisor interaction.

Other Technology As other technology becomes available (such as proximity detection, light
vehicle monitoring, etc.) and is found through testing to be a viable option,
sites will implement on a case-by-case basis with the assistance of the FCX
Technology Center.

5.0 Training

All training will be documented and records maintained.

Visitor Awareness Must be provided to all visitors who have or may have the potential to be
Training (Hazard present in areas where heavy equipment will be operated. This training shall
Awareness) include an overview of the hazards of the area.

In-Pit Driver All employees, or contract employees, that will drive in the pit, as specifically
defined by each property, will receive in-pit driving safety training prior to
being allowed to drive on mine haul roads. A certificate, driver’s license,
sticker or some sort of identification will be used to limit access into these
areas.

This driver training will only be provided to those that request and receive
mine area management approval for the training.

If an individual does not have in-pit driver certifications, they will need to be
escorted into the pit.
 Driving in the pit at night introduces additional hazards and should be
addressed in the training materials and practice.

Note: In-pit driving training is not the left-hand driving training done in annual
refresher. It is a specific task training requirement to authorize drivers for pit
access.

Light Vehicle Only Employees, or contract employees, that will only utilize Light Vehicle Access
Access or Left-Hand routes will receive training in safe operation of these routes (could also be
Drive Training known as “left-hand” driving training.) Having this training will not qualify a
driver to drive on mine haul roads.

GSR Refresher Annual GSR refresher training must be provided to affected employees, and
contractors who are authorized, competent or qualified to perform tasks in
areas where interaction with heavy equipment occurs. It must include a
review of existing policies and regulations and shall review any new or
existing hazards and mitigations.

6.0 Audits

Periodic unannounced audits and scheduled audits are expected to ensure compliance with the
policy and safety of personnel. All audits are to be documented, an action plan developed to address
any identified gaps, and actions assigned and tracked to completion. Documents will be retained per
the FCX Corporate Record Retention Policy.

Monthly Each site to develop an audit schedule for area leaders and employees to audit
selected elements of this policy at a frequency appropriate to the frequency of
light vehicle and personnel exposure to heavy mobile equipment.

Quarterly Quarterly Gap Analysis will be performed by a site cross-functional team such
that by the end of a 12 month period, the entire Gap Analysis has been
completed internally. Action items will be generated, as needed, and tracked
to completion.

Annual An annual audit will be scheduled at each site and will be conducted by a
Freeport-McMoRan cross-functional team.

Audits will include review of compliance with FCX policies, training, site SOPs,
and field practices. Follow-up audits may be conducted more frequently
depending on site performance.

A standard format will be used for the annual site audits.

7.0 Variance
If any part of this policy cannot be followed, an approved variance is required. The FCX Variance
Policy will be followed. GSR Variance Process.pdf. Seek assistance from site Health & Safety as
needed.

8.0 Definitions

Definitions

Blind Area or Blind A blind area, or blind spot, is the area around a vehicle or piece of heavy
Spot equipment that is not visible to the operator, either by direct line-of-site or
indirectly by use of internal and external mirrors.

Critical Controls A device, system, or process implemented to eliminate or reduce the

risk for a task/job, but if missing or overlooked has the potential to
lead to catastrophic outcomes such as serious injury or death.

Critical Risks A risk that if not controlled has the potential to lead to catastrophic outcomes
such as serious injury or death.

Grade (Gradient) The degree of inclination or rate of descent or ascent in a roadway.

Heavy Mobile Large equipment used in mining and construction as defined in Section 1.0 of
Equipment this document.

Intersection A place where two or more roadways meet, especially when one is a major
road.

Light Vehicle Smaller single or multi-passenger vehicles and equipment typically less than
one-ton. This can include cars, pick-up trucks, vans, buses, UTVs and ATVs,
and small equipment such as forklifts or bobcats.

Positive Radio As used in this document, defines the radio communication between two
Contact persons identifying themselves and responding one to the other to establish
an understanding of the action each is about to take with relation to
approaching or passing heavy mobile equipment.

RAMP Tech Remote Access Monitoring Process Technician

Right-of-Way The right to proceed with precedence over other vehicles in a particular
situation. For this document at an intersection or along a road.

Tie-downs (Q-point) The place where heavy mobile equipment is parked or staged such as a ready
line.
Turnouts (Orejas) An area provided along a mining road that allows the driver to turn in and
square up with road to allow better sight of other vehicles before turning.
See Appendix for example.

9.0 References
Throughout this Policy other policies and procedures are referenced.

Reference FCX – Lockout Tagout Tryout Policy

Documents FCX – Records and Retention Policy
FCX – Bus Policy
FCX – Variance Process

10.0 Records

The following  Employee Training Records

records must be
retained according
to the FCX Records
Retention Policy
 Annual program review
 Equipment inspection records
 Variance Documents
 Management of Change forms
 Others as described in FCX Records Retention Policy

11.0 Revision History

2015 Initial Release

NEW

Dec 2016 Rev. 1 Adoption of FCX Standard GSR format - 2016

Dec 2016 Rev. 1 Replaced various occurrences of segregation with separation

Dec 2.3 Roles & Resp. – Modified the sentence: “Ensure that a risk review is completed
2016 Supervisors – Identify for any new roads, changes in traffic patterns, or other mine
Critical Risks & Critical changes to ensure that controls are in place.”
Controls To read “… or other changes which could impact safe interaction
of heavy equipment with light vehicles or pedestrians to ensure
that controls are in place.”

Dec 2.6 Roles & Resp. – Revised the sentence: “Supervisors and/or Health and Safety
2016 Employees – Representatives must be immediately contracted if hazardous
Communicate conditions or actions arise which may cause injury to any
Hazardous Conditions employee before proceeding with further workplace activities.”
 To read: “Employees are expected to correct or report to
Supervisors and/or Health & Safety Representatives if hazardous
conditions or actions arise ….”

Dec 2.6 Roles & Resp.- Replaced the sentence: A pre-task risk assessment should
2016 Employees – Perform include critical controls identified for this specific risk (Ex., job
Pre-task Risk hazard analysis, job safety analysis).
Assessments To read: “Critical controls should be identified using the
appropriate tools (ex: pre-shift equipment inspection, work area
inspection, job hazard analysis, job safety analysis.)

Dec 3.1 Separation of Modified various occurrences of “LVAs” to “LVA roads”.

2016 Heavy Equipment and
Light Vehicles – Light Removed the sentence “Sites shall evaluate where this is
Vehicle Access Roads appropriate based on the amount of traffic on the haul road
(i.e., if haul trucks enter periodically this can serve as a reminder
to LVAs that haul trucks are in the area).

Dec 3.1 Separation of Restructured the following text:

2016 Heavy Equipment and “For long term projects sites shall evaluate the use of a tunnel for
Light Vehicles – Heavy these crossings. At a minimum, signal lights and/or signs and
Equipment Crossings crossing gates shall be used to control interaction between light
on Highways or other vehicles and heavy equipment.
Non-mine Roads
“A flagger or crossing guard shall be present to manage the
intersection for all public roadways.

“Where applicable, ensure that Department of Transportation or

other regulatory agencies are involved in the evaluation and
planning.”

To read:
“Where significant interaction or anytime haul traffic crosses
public roads:
 Evaluate the use of a tunnel for these crossings. Or at a
minimum, signal lights and/or signs and crossing gates
shall be used to control interaction between light
vehicles and heavy equipment.

 A flagger or crossing guard shall be present to manage

the intersection for all public roadways.

Ensure that Department of Transportation or other regulatory

agencies are involved in the evaluation and planning and proper
permits are acquired.”

Dec 3.1 Separation of Modified the sentence: “The operator is required to be out of
2016 Heavy Equipment and the cab before others approach the equipment and are out of the
Light Vehicles – operator’s line of site.”
 Approaching Heavy To read: “Operators of haul trucks, loading units, water trucks
Equipment (and other equipment as determined by site) are required to
secure the vehicle and be out of the operator’s cab before
others approach the equipment. Visual contact is to be
maintained with those approaching.”

Dec 3.2 Separation of Modified first paragraph: “All ground personnel shall wear PPE
2016 Heavy Equipment and required for the area as well as a high visibility reflective vest.”
Pedestrians – Ground To read: “All ground personnel shall wear PPE required for the
Crews (leaching, area as well as a high visibility and reflective vest or reflective
surveyors, cable crew) clothing. This clothing needs to be highly visible both day and
night.”

Modified last paragraph by adding the words: “or Control Room

at the end of the sentence.

Dec 3.2 Separation of Modified the last sentence by adding the underlined:
2016 Heavy Equipment and A high visibility and reflective vest or reflective clothing will also
Pedestrians – Flaggers be required.
or Spotters

Dec 3.2 Separation of Modified the last sentence by adding the underlined:
2016 Heavy Equipment and Employees and contractors on the ground around heavy
Pedestrians – Personal equipment or light vehicles shall wear a reflective safety vest or
Protective Equipment reflective clothing except in designated areas such as shops,
parking lots for personal vehicles, secured perimeters and other
designated areas.

Dec 3.3 Tie-down (Q- Added the following to the first bullet:
2016 points) – Minimum (Note: loading equipment may be parked with
Requirements matched haul trucks)

Modified the following bullet with text underlined and a

clarification point in parenthesis:
 Forward travel only for exiting equipment (note: ok to
back into parking ditch)

Modified the following bullet replacing the minimum distance

from 20 feet to 15 feet
 There shall be a minimum of 15 feet between haul
trucks when parked side-by-side; additional clearance
will be needed for “in-line” parking based on size of
equipment
Replaced the word driver to read personnel in the bullet below:
 Slots shall be provided in berms for personnel to enter
and exit
Dec 3.3 Tie-down (Q- Modified the sentence “Haul trucks will not leave the tie-down
2016 points) – Shift Change area until the employee transport vehicle leaves the area.”
Procedures To read: “Haul trucks will not enter or leave the tie-down area
until the employee transport vehicle leaves the tie-down area.
Other activities away from Tie-down area may proceed as
normal.

Modified last paragraph “Each site will develop procedures for

non-routine situations where there is a stray driver or truck that
was not at the tie-down area at the appropriate time, unless
directed to do so by dispatch or supervisor. The shift supervisor
shall direct this effort and conduct a follow-up to determine
actions to prevent a reoccurrence.”
To read
“Each site will develop procedures for non-routine situations
where there is a stray driver or heavy equipment that was not at
the tie-down area at the appropriate time.”

Dec 3.4 Roads & Deleted the following bullets:

2016 Intersections – Haul  Haul roads should be constructed with a substantial
Road Construction base of rock or other material to prevent rutting, pot-
holing, and the development of soft spots in the road.
 Haul roads will have a surface layer of crushed rock or
other suitable road building material to ensure a smooth
surface.
 All roads should be regularly bladed to ensure a smooth
surface.

Modified the paragraph “Haul roads should be constructed at

10% grades or lower. Grades steeper than 10% should be
minimized and shall not exceed 15%. Grades may need to be less
than 10% due to safety considerations. Utilize the
manufacturer’s recommendations for the maximum grades of
articulating trucks used on site.”
To read:
“Haul roads should be constructed at 10% grades or lower
where specific safety considerations determine lower grade
design requirements. Grades steeper than 10% should be
minimized and shall not exceed 15%. Utilize the equipment
manufacturer’s recommendations for the maximum grades of
articulating trucks used on site.”

Deleted the paragraph “Haul roads should be built using a

consistent linear grade to reduce haul truck transmission shifts
and to reduce spillage onto roads. Where grade changes are
necessary, they should be as smooth as possible to avoid racking
the haul truck frame.”
Dec 3.4 Roads & Modified the paragraph “An intersection refers to anywhere
2016 Intersections – multiple haul roads intersect or light vehicle roads meet a haul
Intersections road. Light vehicle support equipment access to haulage roads
must have consideration for adequate line of sight for haulage
traffic.”
To read: “An intersection refers to anywhere multiple heavy
equipment roads intersect or where light vehicle roads meet a
road used by heavy equipment. Light vehicle support equipment
access to haulage roads, and other heavy equipment roads,
must have consideration for adequate line of sight to heavy
equipment.”

Modified the sentence “The right-of-ways (ROWs) should be

adequately signed and included in training. The following
vehicles have ROW:”
To read: “The right-of-ways should be adequately signed and
included in training. The following vehicles have right-of-way
over light vehicles:”

Dec Modified the paragraph “Speed limits shall be set based on

2016 equipment manufacturer recommendations with haul roads
being no more than 35 mph and shops areas in the 10-15 mph
range depending on pedestrian and light vehicle traffic in the
area.”
To read: “Speed limits shall be based on equipment
manufacturer recommendations but with haul road speed limits
being no more than 35 mph and shop area speed limits at 5-15
mph depending on pedestrian and light vehicle traffic in the
area.”

Dec 3.4 Roads & Modified the paragraph: “Permanently closed roadways need to
2016 Intersections – Haul be bermed off. Haul truck tires can be used to temporarily
Road Operations restrict access to haul trucks and large water trucks.”
To read: “Permanently closed roadways shall be bermed off.
Haul truck tires may be used to temporarily restrict access to
haul trucks and large water trucks.”

Dec 3.5 Passing Modified the sentence: “Passing haul trucks or other equipment
2016 Procedures – Haul on the left side in left-hand traffic areas shall not be permitted.”
trucks To read:
Passing haul trucks on the left side in left-hand traffic areas shall
not be permitted.

Dec 3.6 Light Vehicle Modified the sentence: “Light vehicles will have numbering with
2016 Requirements – a minimum size of 4 inch lettering on each front quarter panel,
Minimum and one on the rear when available.”
requirements for pit
entry
 To read: “Light vehicles will have numbering with a minimum
size of 4 inch lettering on each side of the vehicle, with one on
the rear when possible.”

Modified the sentence: “All-terrain Vehicles (ATVs), Utility

Terrain Vehicles (UTVs) and slow-moving small equipment must
be escorted when operating on mine haul roads.”
To read: “All-terrain Vehicles (ATVs), Utility Terrain Vehicles
(UTVs) and slow-moving small equipment must be escorted or
have working amber strobe light when operating on mine haul
roads.”

Dec 3.7 Perimeter Security Modified the sentence: “Other heavy mobile equipment will use
2016 and Lockout tagout established procedures to signify that the equipment is under the
Tryout of Equipment – possession of an operator that is on the ground.”
Pre-use inspections To read: “Large loading equipment, water trucks, and drills also
and Ground Breaks shall have a perimeter security procedure established.”

Dec 3.7 Perimeter Security Replaced the following text: “When maintenance is being
2016 and Lockout tagout performed and when the truck is being fueled, lockout tagout
Tryout of Equipment – tryout procedures according to the FCX – Lockout Tagout Tryout
Maintenance and Policy must be followed for anyone that will get on, under or
Fueling work on the heavy mobile equipment.”
To read: “When maintenance is being performed on any piece of
equipment, lockout tagout tryout procedures according to the
FCX – Lockout Tagout Tryout Policy must be followed for anyone
that will get on, under, or work on the heavy mobile
equipment.”

Dec 4.0 Equipment – Deleted the section: “As other technology becomes available
2016 Technology - Cameras sites should evaluate the implementation of backup cameras on
all heavy equipment that has a large blind spot to the rear of the
vehicle.”

Dec 5.0 Training – Visitor Added this sub-section to the Training section: “Must be
2016 Awareness Training provided to all visitors who have or may have the potential to be
(Hazard Awareness) present in areas where heavy equipment will be operated. This
training shall include an overview of the hazards of the area.”

Dec 5.0 Training – In-pit Modified the paragraph: “All employees that will drive in the pit
2016 Driver will receive in-pit driving safety training prior to being allowed to
drive on mine haul roads. A certificate, driver’s license, sticker or
other means of identification will be used to limit access into
these areas.”
To read: “All employees, or contract employees, that will drive
in the pit, as specifically defined by each property, will receive
in-pit driving safety training prior to being allowed to drive on
mine haul roads. A certificate, driver’s license, sticker or some
 sort of identification will be used to limit access into these
areas.”

Modified the sentence: “This driver training will only be provided

to those that request and receive management permission for
the training.”
To read: “This driver training will only be provided to those that
request and receive mine area management approval for the
training.”

Added the following text: “Note: In-pit driving training is not the
left-hand driving training done in annual refresher. It is a
specific task training requirement to authorize drivers for pit
access.”

Dec 5.0 Training – Light Modified the text: “Employees that will utilize Light Vehicle
2016 Vehicle Only Access Access routes will receive training in safe operation of these
routes. Having this training will not qualify a driver to drive on
mine haul roads.”
To read: “Employees, or contract employees, that will only
utilize Light Vehicle Access routes will receive training in safe
operation of these routes (could also be known as “left-hand”
driving training.) Having this training will not qualify a driver to
drive on mine haul roads.”

Dec 5.0 Training – Modified the text: “For personnel carriers (vans) drivers must
2016 Personnel Transport have a minimum of two years of experience operating
Driver Training equipment before driving personnel transports. They must also
have received training and information on the Q-point
procedures.”
To read: “For personnel carriers (vans), drivers must have a
minimum of two years of experience in their respective
environment before driving personnel transports. Those
personnel van drivers who will enter into mine Q-point areas,
must also have received training and information on the Q-point
procedures; this training is to be documented.”

Dec 5.0 Training – GSR Added this sub-section to the Training section: Annual GSR
2016 Refresher refresher training must be provided to affected employees, and
contractors who are authorized, competent or qualified to
perform tasks in areas where interaction with heavy equipment
occurs. It must include a review of existing policies and
regulations and shall review any new or existing hazards and
mitigations.

Dec 6.0 Audits Added audit requirements for Monthly, Quarterly and Annual
2016 periods.
Appendix A Examples and Forms
 Haul Road Safety Audit Form

Date Haul Road, Pit or Area

Auditor(s)
General Design Considerations YES NO NA COMMENTS / ACTIONS

Is the road free of potholes, rutting, or soft spots?

Is the road’s top surface graded and smooth?

Is the road wider than 3.5 haul trucks (793-85’, 930E-96’)?

Is the maximum sustained grade at or below 10%?

Is the road grade as smooth as possible to minimize gear

shifting?

Are there smooth transitions between grade changes?

Are sharp curves widened & provided with adequate supers?

Are there objects in the line of sight (berms, vehicles, shrubs,

buildings) which restrict visibility?
Are speeds reduced in areas where vertical or horizontal curves
reduce visibility?
Drainage and Dust Control YES NO NA COMMENTS / ACTIONS
Is the road configured with adequate drainage and is it
maintained?

Does the road have adequate cross-fall for drainage?

Are culverts located at low points & intersections which are

capable of retaining water?

Is there adequate dust-control to ensure visibility?

Is water applied appropriately by water trucks by spotting and

not over-watering?
Berms and barriers YES NO NA COMMENTS / ACTIONS

Are berms at least mid-axle height?

Are berms near the base of steep ramps or significant drop offs
higher and wider than normal?

Are berms de-rocked?

Are center berms installed at sharp curves, critical intersections

and areas of increased speeds/risk?

Are closed sections of roads properly restricted from entry?

Safety Enhancements YES NO NA COMMENTS / ACTIONS
Are there signs indicating the proper speed and/or grade for the
road?
Are there signs indicating intersections, narrow spots, rough
sections, or other pertinent information?
Are the signs in good shape and readable to the operators of
large haul trucks?

Are there guideposts on the side of the road?

Are there rock slots available for storing spillage?

Is pedestrian access prohibited? If not, are pedestrian walkways

physically separated from haul truck traffic?

Is light vehicle traffic physically separated from haul truck traffic?

Are there run-away truck ramps for downhill loaded sections?

Intersections YES NO NA COMMENTS / ACTIONS

Are the speed limits approaching the intersection appropriate?

Is at least 300ft of sight distance available at intersections

located on grades in excess of 6%?
Is at least 175ft of sight distance provided at intersections
located on flat terrain?
Are intersections located on straight and flat terrain as much as
possible?

Are intersections configured as right angle intersections?

Is lighting appropriate for the intersection? Is lighting needed at

night? Is it directed away from the operator’s line of sight?
Are there objects in the line of sight (berms, vehicles, shrubs,
buildings) which restrict visibility?
Are there any powerlines, pipelines or other utilities near the
intersection?

Is there a queue point near the interchange?

Is light vehicle traffic physically separated from haul truck traffic

as much as possible?
Are special accommodations made for light vehicles? (e.g.
turnouts or orejas “ears”, special turn lanes, elevated roadways)
Is pedestrian access prohibited? If not, are pedestrian walkways
physically separated from haul truck traffic?
What controls are in place to control vehicles? (e.g. traffic lights,
stop signs, yield signs, physical controls)
Are center berms in place or needed to direct light vehicles and
haul trucks into the appropriate lanes?
Are there drainage controls in place to keep the intersection
dewatered?
Has the intersection been planned? Is it built according to the
design?

General COMMENTS / ACTIONS about Haul Road:

Diagram / Drawing:
Safford Mine Tie Down Example

Photo 1

Photo 2
Cerro Verde Turnouts (Orejas)

Photo 1

Photo 2